Coolant leak, what is this part?

[08HybridOK]

So I've been smelling antifreeze when I get out of the truck the last few days. Finally tracked it down (I think) to whatever this part is (attached video) near the alternator, has a hose coming out & goes toward the firewall (I assume feeding the heater core(s))

It's dripping, a pretty good drip... drip now.

So what is this part? How do I fix it? Can I drive a few dozen more miles as is. If its difficult to fix, whats an approximate repair bill? ($100, $1000)?

leak - YouTube

 

[toms89]

Click following link..

http://www.expeditionforum.com/f42/need-engine-part-identified-21092/

 

[stamp11127]

This doesn't help you in any way but for those of us that work on big trucks, the audio sounds just like an air line leak. Had me going there for a second...

 

[08HybridOK]

Sorry; audio not needed. just had my cell with me. wind/fan blowing.

So it seems like a complete intake manifold needs replacing?

Might as well have the plugs done too. Might be a tad over my comfort level.

 

[GaExpedition]

It's not as bad as it looks. If your able to do basic mechanic type work, you can do this too. Wish I had went ahead and changed the plugs on mine while I had it down that far. Would have made changing them a piece of cake, but since she was running great on the ones I had, I didn't. It can be done with basic hand tools, pliers, screwdriver, etc. The only two things I used some folks may not have readily on hand was a small battery drill, and a gasket remover brush that fits in the drill. I had my son hold a small wet/dry vac right next to the brush while I used it to remove the old gasket material.

 

[08HybridOK]

Is this a pretty close video?

Ford Lincoln Mercury 4.6L Intake Manifold Replacement Part 1 - YouTube

 

[GaExpedition]

Yep, pretty much the same with subtle differences. One being the motor sits a little farther back on an expy making a few things harder to get to.

 

[FordandPolaris]

Whether you pay someone to do it, or do it yourself, definitely do the plugs while you are in there. Those are a pain in the butt on the 5.4

 

[08HybridOK]

Thanks; unless I find a willing helper; I'm leaning towards taking it to a dealer.
Quoted $1550 for both intake & plug jobs, at $600 in parts for the intake & gasket, & $50 for the plugs (Really?!?!) But he said would install my parts if I brought them in (ie $170 for the intake & gaskets on amazon & $3.50plug at autozone).

So I'm assuming $800-1000 in labor. I know it's a lot of work/time consuming. But I know my skill level too. I could do it; but I'd screw something up and not have a working vehicle, or worse drop something into the open engine & trash the whole thing!

 

[08HybridOK]

Since I"m leaning toward a dealer; and its at 90K; what else should I have done while it's in?

The service guide says change the PCV, what's that, and should I?
I think I saw online about a waterhose that runs under, thru, something the intake; is that apply to my 5.4, should it be replaced?
The intake I ordered has a new thermostat & gaskets.
Change the tranny fluid

Any other suggestions?

 

[Expyguru]

Take you're chances yourself you could screw it up 10 times before it cost you a grand, that's a crazy price. Its not hard just take a lot of pics as you tare down. I have seen where you can replace that metal hose with a rubber coolant hose without removing the intake. Seen on you tube. Ill try to find some links

 

[08HybridOK]

Take you're chances yourself you could screw it up 10 times before it cost you a grand,

Unless I drop something into the engine & trash the whole thing... Wouldn't plan on that tho!

that's a crazy price. Its not hard just take a lot of pics as you tare down. I have seen where you can replace that metal hose with a rubber coolant hose without removing the intake. Seen on you tube. Ill try to find some links

The only 'easy' video I found was the hose under the intake; a guy elbows it and runs it around the outside. Mt leak is under I guess whats called a water crossover(?)
I haven't seen any reports of just fixing the leaking seals. But I'm all eyes if you can save me major cash!

 

[08HybridOK]

Ok, I think I'm gonna try it, of course now that the temps dropped from 70s to 20s!

That video I posted, shows a bracket in the far back, is that on mine?

How did he clean the old block up?

Do the parts stores rent a plug extractor tool?

 

[FordandPolaris]

Ok, I think I'm gonna try it, of course now that the temps dropped from 70s to 20s!

That video I posted, shows a bracket in the far back, is that on mine?

How did he clean the old block up?

Do the parts stores rent a plug extractor tool?

I am purely going off the memory of the little renting tool mat at O'Reilly but I want to say they do. Doesn't hurt to call and ask. They get that question a lot I am sure.

Oh and I saw earlier you asked about PCV. The Positive Crankcase Ventilation (PCV) valve plugs into the top of the valve cover and leads to the intake manifold, usually on the back. They can get a hole in them and cause a rough idle if too old.

 

[Expyguru]

Unless I drop something into the engine & trash the whole thing... Wouldn't plan on that tho!




The only 'easy' video I found was the hose under the intake; a guy elbows it and runs it around the outside. Mt leak is under I guess whats called a water crossover(?)
I haven't seen any reports of just fixing the leaking seals. But I'm all eyes if you can save me major cash!

I would try my luck at the replace it with a hose first. Seems a lot easier

 

[08HybridOK]

Well I got the old intake out; now to figure out how to clean up the, cylinder head? so I can start putting it back together.

I'm still on the fence about the plugs. They should be replaced; but they break off, not sure I want to tackle 2 major repairs at the same time (harder to track down a problem if there is one)

Good news, the new intake dropped $20 on amazon & they gave me a refund!

SO far the hardest parts were the back pass bolt on the intake, the egr nut & the power steering lower bolts.

Hope today's reinstall go smooth.

 

[08HybridOK]

In case anyone folowing/helping me out here & doesn't see the new post I made:

Replaced the intake manifold to fix the water crossover leak.

Put it all back togather, started right up! Great!

But after a min it almost stalled; then idled low & rough/sputtery.

Rev it, it's fine for a min or 2 then same thing.

Drove it a mile & back; drives great, no issues up to 70mph.

get back in garage; wait a min or 2 and it starts again.

Taking a lunch break, will go back over my pictures; but 98% sure I put it all back togather correct.

I only replaced the intake, I put the same injectors & coils back in; left the plugs alone to (probably gonna regret that soon)

No code on my Scangauge, no idiot lights either.

????

{Update 1}

It looks like all the right parts are back on the right places. It sounds like it's sucking in more air than before (maybe?)
BUt I definatly see some fuel spraying in the back pass injector area. Definatly need to fix that first. {I think I just need to lift the rail & re-seat the top O ring, as at one point of re-assemble it lodged into the rail. I didn't think about it then}

 

[GaExpedition]

I posted this in the other thread, but in case you come here first. The o-ring you found in the parts/screw package goes on the plastic elbow that twist locks on the back of the manifold to prevent a vacuum leak. That sounds like what your hearing, and whats causing the intermittent rough idle. Also, you can get a 4 pack of injector o-rings to fix the leaky one at the parts store for about 5 bucks.

 

[08HybridOK]

T H A N K Y O U EVERYONE!!!!

It was that PCV elbow piece in the new intake. My instruction sheet from Dorman doesn't mention the o-ring, just "point toward pass side, lower into intake, turn clockwise to lock." Grrrrrr

Only had remove the TB to swing it out of the way to get to it, so I didn't take to long to fix it.

Then popped off the fuel rail, pulled the o-ring out of the rail; popped it back on the injector. and it appears that is fixed too!

Should have asked earlier; but the injectors just sorta 'sit' there? I kinda expected to need to 'force' them down into the intake until there was a pop, or some 'firm' feeling. So they kinda 'float' under the rail and on the intake? And tightening the rail 'locks' them into place?

Thanks again to all who helped and encouraged me, and wound up saving me like $1200-$1400!!!


BTW; at least at my local stores; do not rent the plug extractor. $99.99 to buy one.

I wussed out on that project for now. scared of dropping porcelain pieces into the engine.